Fungo Netherlands has develop an automated filter technology. The integrated system (silo-wood pellets – blending – pasteurizing – bagging- repining) is now for sale. A production of 4.500 substrate bags takes 1.5 persons to operate. The complexity of making wood-based substrate is with the automated filter bag technology an issue of the past www.youtube.com/watch?v=CjMTKZqA0g8
Our preferred raw materials are organic wood pellets combined with organic protein pellets.These pellets can be stored in silo’s and automatically filled into a blender. More over pellets give a very standardized product which enhances the yield and consistency. Lose sawdust and protein material are an option as well
Wood based substrates are not necessarily “selective” like compost is for white button mushrooms. Therefore, bulk filling and/or perforated bags are very risky and rather expensive considering the amount of cleaning, hygiene standards and investments to be made. The inhouse developed and patented filter technology is crucial for a low-cost operation and a standardized product. In addition, wood-based substrate give a much better quality product and better shelf life than bulk-based wheat-straw.
We export mushroom substrates worldwide from our production facilities in Malaysia and/or The Netherlands.
This newly developed blending technology has three major process steps of which the first two parts are truly innovative and “game changing”. The first step is the most complex part of which filling, blending, heating/pasteurizing, cooling, inoculation and bagging all takes place in one single process-step in 200 square meter clean room environment. This part of the process is fully automated and PLC & computer controlled. This innovative first process step takes 6-12 hours and 4 FTE’s for a 16 MT daily substrate production.
The ripening phase, depending on the mushroom type, takes anywhere between 4 and 6 weeks. The reason for this very short ripening cycle is the proprietary- developed filtration/bag technology, for a self-regulating oxygen /Co2 exchange between substrate and environment. Blender version 2.0 has the same capital outlay as Blender version 1.0 yet runs at a double operating capacity. https://youtu.be/yDcTA0l9TOA
The protein pellets is a mixture of three ingredients for maximum yield.
"The closed system produces 4.500 bags per batch. Each bag is 1.8 kg. It is possible to run two batches per day. To operate the system, it takes only two full time employees, which makes the system the lowest cost producer in the market today."
"Depending on the cost of energy in your country, the labor cost and the cost of raw material, the substrate cost will be anywhere between US$ 280, -- and US$ 500 per 1000 kg substrate produced. Considering that you can pick 250 kg fresh mushrooms from 1000 kg substrate,the substrate cost per kg fresh mushroom is therefore between US$ 1.12 and US$ 2, -. (not including cultivation/picking and packing cost)."
"From 1000 kg substrate, you can expect 250 kg of shitake/Eringy. Or a bag of 1.8 kg substrate will provide 450 grams of fresh mushrooms. More importantly all this yield comes in one flush, or in 10 days of cultivation."
"The spawn run for shitake /Eringy takes 14 days. The repining time for shitake takes another 4 to 5 weeks, thus in total 6 to 7 weeks for shitake. For Eringy the ripening takes another 3 weeks, thus in total 5 weeks.
This very short ripening phase, requires little room compared to more traditional technologies where ripening time for shitake can take up to 24 weeks or more. Therefore, the factory pace is limited, hence investment savings
The reason for such a short ripening phase is the inhouse developed filter technology. The bags have a very large filter which exchanges gasses like Co2 and Oxygen very rapidly and accelerates mycelium growth and maturity."
"We encourage you to work with hard wood pellets. The reason for working with pellets is that they are clean and dry (9 % moist). Your raw materials are thus standardized which results in a very consistent end product and thus yield. Yet you can also work with “loose” sawdust.
We can ship pellets to anywhere in the world or you can source locally. For the protein pellets we can provide you with certified organic pellets.
For the plastic and filter we recommend you directly to buy from us since the plastic and filter material are synchronized with the bagging machine. You can however buy your own filter and plastic material anywhere in the market if you would like to."
"Most 2 kg bags with a filter cost US$ 15 cent per bag, which you than need to fill by hand. With the integrated & automated filter technology a bag cost US$ 4 cent. With a daily production of 4.500 bags that makes a difference of US$ 180.675, -- per year.
In addition, normally it would take at least two to three full time employees to run a batch of 4.500 bags per day. The automated bagging machines takes zero employees. This is of course an additional cost saving.
Further, the filter surface is 30+ X larger than the existing filter bags on the market, since most filters are protected by micro perforated plastic on the inside, limiting gas exchange."
"About 0.1 %. Or from a Batch of 4.500 bags daily 4 to 5 bags might have a heat-seal which is not fully closed."
"Yes, only a very small one. The bagging machine will operate in a clean room."
"Yes, you are welcome, by appointment, at our plant in the Netherlands or our plant in Malaysia."
"We tried micro perforation for a very long time and failed. Micro holes are still 50 ums large while a bacterium is maybe 2 ums. This is like scoring for open goal. The infection rates are high and/or the cost of clean rooms and/or cleaning or are very high. Automated filtered bags are cheaper than micro perforation, why take the risk and spent so much on clean rooms?"
"The system size depends on your market. A common system produces 8000 kg substrate per batch. We have developed systems where you can run two batches per day. A smaller system is not necessary much cheaper since the peripherals like steam boiler, cooling system and bagging machine are more or less the same in price, regardless of the capacity/size."
"Yes. We design a system for you according the space you have available. We provide you with CAD drawings and production capacity possibilities which suits your environment. We come and install the whole system at your place. We start the project together with you and provide an engineer to have the system fully running before we leave."
"You don’t need many. The blender runs at very low RPM (4 rpm/minute) and therefore requires little maintenance. There are a very few moving parts in the whole system. The bagging machine needs a few simple easy to replace spare parts which we provide. Most parts we can sent by DHL or you can buy locally."
"For an 8000 kg daily production, 7 days a week, 365 days a year you need about 4300 square meters of surface. That includes the cultivation rooms for about 2000 kg fresh shitake."
"Yes. We can provide you with Skall certified protein organic pellets if needed. We can ship 28 MT in a 20” dry container, which is inexpensive anywhere in the world. For the wood pellets or saw dust you need to make sure no paint or chemicals are mixed."
Please fill out the form below to send us an email and we will get back to you as soon as possible.
AddressHorsterdijk 102 5973 Lottum
Phone +31 (0) 657-767-015 / +31 (0) 773-661-439